Wall structure

ABSTRACT

A wall structure with a first dampening element (A) includes at least one layer ( 20,20   a - c ) configured to form an acoustic inner surface and/or to dampen sound; a first stopping element (B) including at least one layer ( 30 ) configured to stop sound; a second dampening element (C) including at least one layer ( 40,40′,50 ) configured to form an acoustic inner surface and/or to dampen sound; and a second stopping element (D) comprising at least one layer ( 60 ) configured to stop sound; wherein the layers of the first (A) and second (C) dampening element comprise porous and/or open cell material.

TECHNICAL FIELD

The present application generally relates to a wall structure. Inparticular, but not exclusively, the present application relates to asoundproof and acoustical wall structure, especially for relativelysmall spaces.

BACKGROUND

This section illustrates useful background information without admissionof any technique described herein being representative of the state ofthe art.

Various wall materials and structures have been developed forsoundproofing purposes. Furthermore, various acoustical surfacematerials, such as acoustical panels and fabrics, have been developed toimprove the sound quality or characteristics in a space.

In small spaces, such as in phone booths or conference rooms foropen-plan offices, the soundproofing and sound quality is of foremostimportance and challenging to control because of space restrictions.

Existing solutions for soundproofing and acoustics are often expensiveor difficult to assemble. Furthermore, they often require lot of spaceleading to bulky and unwieldy structures.

The aspects of the disclosed embodiments aim to mitigate thedisadvantages of the prior art by providing a compact soundproof wallstructure that also ensures sound quality in the soundproofed space.

SUMMARY

Various aspects of examples of the aspects of the disclosed embodimentsare set out in the claims.

According to a first example aspect of the aspects of the disclosedembodiments, there is provided a wall structure, comprising

a first dampening element comprising at least one layer configured toform an acoustic inner surface and/or to dampen sound;

a first stopping element comprising at least one layer configured tostop sound;

a second dampening element comprising at least one layer configured toform an acoustic inner surface and/or to dampen sound; and

a second stopping element comprising at least one layer configured tostop sound; wherein

the layers of the first (A) and second (C) dampening element compriseporous and/or open cell material.

The at least one layer of the first stopping element may comprise metal.

The at least one layer of the first stopping element may have athickness between 0,5 and 2 mm, preferably of 1 mm.

The at least one layer of the second stopping element may comprisematerial chosen from the group of plywood, hardboard, plastic,composite, metal and a combination thereof.

The at least one layer of the second stopping element may have athickness between 5 and 15 mm, preferably of 9 mm.

The first dampening element may comprise a first layer comprising porousor open cell material and a second layer comprising porous or open cellmaterial.

The material of the first layer may have a density between 50 and 250kg/m³, preferably between 150 and 250 kg/m³ and most preferably about200 kg/m³ and the material of the second layer may have a densitybetween 10 and 100 kg/m³, preferably between 30 and 50 kg/m³ and mostpreferably of about 40 kg/m³.

The first layer may have a thickness between 5 and 15 mm, preferably of10 mm and the second layer may have a thickness between 30 and 50 mm,preferably of 40 mm.

The second dampening element may comprise a fourth layer comprisingporous or open cell material and a fifth layer comprising an air gap.

The material of the fourth layer may have a density between 10 and 150kg/m³, preferably between 60 and 100 kg/m³ and most preferably of about80 kg/m³.

The fourth layer may have a thickness between 20 and 40 mm, preferablyof 30 mm and the fifth layer may have a thickness between 5 and 15 mm,preferably of 10 mm.

The wall structure may further comprise a frame element at both ends ofthe structure.

According to a second example f the aspects of the disclosedembodiments, there is provided a phone booth, comprising wallscomprising the wall structure of the first example aspect.

According to a third example of the aspects of the disclosedembodiments, there is provided a method of manufacturing the wallstructure of the first example aspect by

providing the frame elements;

providing the first dampening element;

providing the first stopping element;

providing the second dampening element; and

providing the second stopping element.

Different non-binding example aspects and embodiments of the aspects ofthe disclosed embodiments have been illustrated in the foregoing. Theembodiments in the foregoing are used merely to explain selected aspectsor steps that may be utilized in implementations of the aspects of thedisclosed embodiments. Some embodiments may be presented only withreference to certain example aspects of the present disclosure. Itshould be appreciated that corresponding embodiments may apply to otherexample aspects as well.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of example embodiments of the presentdisclosure, reference is now made to the following descriptions taken inconnection with the accompanying drawings in which:

FIG. 1 shows a principle view of a phone booth for example in which anembodiment of the present disclosure is used;

FIG. 2 shows a schematic view of a cross section of a wall structureaccording to an embodiment of the present disclosure;

FIG. 3 shows a further schematic view of a cross section of a wallstructure according to an embodiment of the invention;

FIG. 4 shows a further schematic view of a cross section of a wallstructure according to an embodiment of the present disclosure;

FIG. 5 shows a further schematic view of a cross section of a wallstructure according to an embodiment of the present disclosure; and

FIG. 6 shows a flow chart of a method of manufacturing a wall structureaccording to an embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE DRAWINGS

The aspects of the disclosed embodiments and its potential advantagesare understood by referring to FIGS. 1 through 6 of the drawings. Inthis document, like reference signs denote like parts or steps.

FIG. 1 shows a principle view of a phone booth for example in which anembodiment of the present disclosure is used. The phone booth 100comprises walls 120 and a door 140. The wall structure 200 (FIG. 2 )according to an embodiment of the invention is for example used in thewalls 120 of the phone booth 100. The wall structure 200 according to anembodiment of the invention is further used for example as an additionalstructure on top of an existing wall in order to increase acoustics andsound dampening of the space in which the existing wall is situated.Furthermore, the wall structure 200 according to the invention is forexample used in vehicles, in engine rooms and in encapsulation, housingor casings of different kinds for example for machines.

FIG. 2 shows a schematic view of a cross section of a wall structure 200according to an embodiment of the present disclosure. The cross sectionshown is in direction perpendicular to the wall with the inner surfaceof the wall shown lower and the outer surface shown higher. The wallstructure 200 comprises a first dampening element A, a first stoppingelement B, a second dampening element C and a second stopping element Dthe structure and function of which will be described hereinafter.Furthermore, the wall structure 200 comprises a frame element 10, atboth ends of the structure. In an embodiment, the frame element 10comprises material such as plywood, hardboard, plastic, composite, metalor a combination thereof. In an embodiment, the material of the frameelement 10 has certain characteristics as hereinafter described.

The wall structure 200 in a further embodiment further comprises supportelements 70,80 on both ends of the wall structure 200. In an embodiment,the support elements 70,80 comprise material such as plywood, hardboard,plastic, composite, metal or a combination thereof. In furtherembodiment, the support elements 70,80 are integrated with the frameelements 10.

FIG. 2 further shows the layers of the elements A,B,C,D of the wallstructure 200 configured to provide for the acoustic and soundproofingeffect. In an embodiment, the layers and the elements of the wallstructure 200 are attached to each other in a conventional manner, forexample using glue.

Starting from the inner surface of the wall structure 200, the firstdampening element A of the wall structure comprises a first, or innersurface, layer 20 a configured to provide for the acoustic andsoundproofing effect. The first layer 20 comprises porous or open cellmaterial and is configured to form an acoustical inner surface of thewall with desired acoustical properties, i.e. configured to let certainsound frequencies pass in order to improve the acoustical properties ofthe space. The first layer 20 a comprises material that is resistant towear and permeable to air, i.e. breathing. In an embodiment, the firstlayer 20 a comprises material such as felt, foam rubber, polyesterfibre, glass wool, rock wool, mineral wool, canvas, canvas coveredmaterial or a combination thereof. In an embodiment, the density of thefirst layer 20 a is between 50 and 250 kg/m³, preferably between 150 and250 kg/m³ and most preferably of about 200 kg/m³.

The first dampening element A of the wall structure 200 furthercomprises, after the first layer 20 a, a second, or inner damping, layer20 b configured to provide for the acoustic and soundproofing effect.The second layer 20 b comprises porous or open cell material and isconfigured to absorb and dampen the sound. In an embodiment, the secondlayer 20 b comprises material such as felt, foam rubber, polyesterfibre, glass wool, rock wool, mineral wool or a combination thereof. Inan embodiment, the density of the second layer 20 b is between 10 and100 kg/m³, preferably between 30 and 50 kg/m³ and most preferably ofabout 40 kg/m³.

The first stopping element B of the wall structure 200 comprises, afterthe second layer 20 b, a third, or stopping, layer 30 configured toprovide for the acoustic and soundproofing effect. The third layer 30comprises material configured to stop sound. In an embodiment, thematerial of the third layer 30 comprises metal or medium-densityfibreboard (MDF). In an embodiment, the material of the third layer hasan area density of 5 to 15 kg/m². In a further embodiment, the materialof the third layer 30 comprises steel, lead, or copper. In anembodiment, the third layer 30 is sandwiched between the supportelements 70,80 as shown in FIG. 1 .

The second damping element C of the wall structure 200 comprises, afterthe third layer 30, a fourth, or outer damping, layer 40 configured toprovide for the acoustic and soundproofing effect. The fourth layer 40comprises porous or open cell material and is configured to absorb anddampen the sound. In an embodiment, the fourth layer 40 comprisesmaterial such as felt, foam rubber, polyester fibre, glass wool, rockwool, mineral wool or a combination thereof. In an embodiment, thedensity of the fourth layer 40 is between 10 and 150 kg/m³, preferablybetween 60 and 100 kg/m³ and most preferably of about 80 kg/m³.

The second damping element C of the wall structure 200 comprises, afterthe fourth layer 40, a fifth, or air, layer 50 configured to provide forthe acoustic and soundproofing effect. The fifth layer 50 comprises anair gap configured to form together with the fourth layer a dampened airgap in order to dampen sound.

The second stopping element D of the wall structure 200 comprises, afterthe fifth layer 50, a sixth, or outer, layer 60 configured to providefor the acoustic and soundproofing effect. The sixth layer is configuredto form the outer surface of the wall structure 200 and comprisesmaterial configured to stop the sound. In an embodiment, the sixth layer60 comprises material such as plywood, hardboard, plastic, composite,metal or a combination thereof. In an embodiment, the material of theframe element 60 has certain characteristics as hereinafter described.In a further embodiment, the wall structure 200 comprises one or severaladditional air gaps configured to dampen sound in between the elementsdescribed hereinbefore. In a still further embodiment the air gap 50and/or further air gaps are configured to, in addition to dampeningsound, to be used as channels for electrical wiring and the like.

In an embodiment, for example as the wall structure 200 is used in aphone booth 100 of FIG. 1 , the material of the frame elements 10, theouter layer 60 and the support elements 70,80 comprises material havingcertain characteristics. In an embodiment, the material has a module ofelasticity perpendicular to the surface larger than about 5500 N/mm², amodule of elasticity parallel to the surface larger than about 7000N/mm² and a flexural strength larger than about 33 N/mm².

The wall structure 200 according to embodiments of the presentdisclosure provides for a compact size while retaining soundproofing andacoustical quality. Accordingly, the dimensions of the layers of thewall structure are chosen so that the thickness of the wall structure200 is between 50 and 150 mm, preferably between 80 and 120 mm, and morepreferably about 100 mm. In an embodiment, as an example, the thicknessof the first to sixth layers is as follows

Thickness Range mm Preferred mm 1st layer 20a  5-15 10 2nd layer 20b30-50 40 3rd layer 30 0.5-2 (metal), 7-12 (MDF) 1 (metal), 9 (MDF) 4thlayer 40 20-40 30 5th layer 50  5-15 10 6th layer 60  5-15  9

FIG. 3 shows a further schematic view of a cross section of a wallstructure 300 according to an embodiment of the invention. The frameelements 10, the support elements 70,80 and the third to sixth layers30-60 have a structure as hereinbefore described with reference to FIG.2 . The first damping element of the wall structure 300 comprises at theinner surface thereof a first, or inner surface and damping, layer 20configured to provide for the acoustic and soundproofing effect insteadof the first layer 20 a and second layer 20 b as described withreference to FIG. 2 .

The first layer 20 comprises porous or open cell material configured toform the inner surface of the wall with desired acoustical properties,i.e. configured to let certain sound frequencies pass in order toimprove the acoustical properties of the space. Furthermore, the firstlayer 20 is configured to absorb and dampen the sound. In an embodiment,the first layer 20 a comprises material that is resistant to wear andpermeable to air, i.e. breathing. In an embodiment, the first layer 20 acomprises material such as felt, foam rubber, polyester fibre, glasswool, rock wool, mineral wool or a combination thereof. In anembodiment, the density of the first layer 20 a is between 10 and 250kg/m³ and preferably between 30 and 200 kg/m³.

FIG. 4 shows a further schematic view of a cross section of a wallstructure 400 according to an embodiment of the present disclosure. Theframe elements 10, the support elements 70,80 and the first to third andsixth layers 20 a-30,60 have a structure as hereinbefore described withreference to FIG. 2 . The second damping element of the wall structure400 comprises a fourth, outer damping, layer 40′ configured to providefor the acoustic and soundproofing effect and extending from the thirdlayer to the sixth layer, i.e. there is no air gap 50 (FIG. 2 ) betweenthe fourth layer 40′ and the sixth layer 60.

The fourth layer 40′ comprises porous or open cell material and isconfigured to absorb and dampen the sound. In an embodiment, the fourthlayer 40′ comprises material such as felt, foam rubber, polyester fibre,glass wool, rock wool, mineral wool or a combination thereof. In anembodiment, the density of the fourth layer 40 b is between 10 and 150kg/m³, preferably between 60 and 100 kg/m³ and most preferably of about80 kg/m³.

FIG. 5 shows a further schematic view of a cross section of a wallstructure 500 according to an embodiment of the present disclosure. Theframe elements 10, the support elements 70,80 and the first to sixthlayers 20 a-60 have a structure as hereinbefore described with referenceto FIG. 2 . The first damping element A of the wall structure 500further comprises a further layer, or second inner damping layer, 20 cbetween the first 20 a and the second 20 b layers configured to providefor the acoustic and soundproofing effect.

The further layer 20 c comprises porous or open cell material and isconfigured to absorb and dampen the sound. In an embodiment, the furtherlayer 20 c comprises material such as felt, foam rubber, polyesterfibre, glass wool, rock wool, mineral wool or a combination thereof. Inan embodiment, the density of the further layer 20 c is between 30 and150 kg/m³, preferably between 50 and 100 kg/m³ and most preferably ofabout 75 kg/m³.

A skilled person understands that features of the embodiments describedhereinbefore with reference to FIGS. 2 to 5 are combined into furtherembodiments of the present disclosure, not shown in Figs, for exampleinto an embodiment with the wall structure as described with referenceto FIG. 2 but without the air gap 50. Furthermore, the skilled personappreciates that the first B and/or second D stopping element of thewall structure 200,300,400,500 in a further embodiment comprises severallayers instead of the single one described hereinbefore. For example thethird layer 30, e.g. a steel plate, of the first stopping element in anembodiment comprises a laminate structure with several layers.

Furthermore, the skilled person understands that the use of wallstructure hereinbefore described is not limited to vertical walls, butis readily applicable for example to use in horizontal structures suchas roofs or floors.

FIG. 6 shows a flow chart of a method of manufacturing a wall structureaccording to an embodiment of the present disclosure. At step 610 theframe elements 10 are provided. At step 620, the elements (A-D) with thelayers 20 a-60 are attached in a conventional manner.

Without in any way limiting the scope, interpretation, or application ofthe claims appearing below, a technical effect of one or more of theexample embodiments disclosed herein is providing a compact soundproofstructure for a compact space. Another technical effect of one or moreof the example embodiments disclosed herein is providing an improvedsoundproofing of a wall. Another technical effect of one or more of theexample embodiments disclosed herein is improved acoustics of a compactspace without sacrificing soundproofness.

Although various aspects of the present disclosure are set out in theindependent claims, other aspects of the invention comprise othercombinations of features from the described embodiments and/or thedependent claims with the features of the independent claims, and notsolely the combinations explicitly set out in the claims.

It is also noted herein that while the foregoing describes exampleembodiments of the invention, these descriptions should not be viewed ina limiting sense. Rather, there are several variations and modificationswhich may be made without departing from the scope of the aspects of thedisclosed embodiments as defined in the appended claims.

The invention claimed is:
 1. A wall structure for a limited space, comprising: a first dampening element comprising at least one layer comprising porous or open cell material, wherein the at least one layer comprising porous or open cell material forms an exterior surface of the wall structure, which faces the limited space; a first stopping element forming an opposite exterior surface of the wall structure, the first stopping element comprising at least one layer to stop sound; a second dampening element in between said first dampening element and said first stopping element, the second dampening element comprising at least one layer comprising porous or open cell material to dampen sound, the second dampening element further comprising an air layer that is adjacent to the at least one layer of the second dampening element comprising said porous or open cell material; and a second stopping element in between the first dampening element and the second dampening element and comprising at least one layer to stop sound, the sound stopping comprising stopping sound waves from propagating from one side of the second stopping element to another side of the second stopping element.
 2. The wall structure of claim 1, wherein the at least one layer of the second stopping element comprises a continuous layer of sound stopping material to stop sound.
 3. The wall structure of claim 2, wherein the continuous layer of the second stopping element has a thickness between 0.5 mm and 2 mm.
 4. The wall structure of claim 2, wherein the continuous layer of the second stopping element comprises material chosen from the group of plywood, hardboard, plastic, composite, metal and a combination thereof.
 5. The wall structure of claim 1, wherein said at least one layer of the second dampening element has a thickness between 20 mm and 40 mm, and the air layer has a thickness between 5 mm and 15 mm.
 6. The wall structure of claim 1, further comprising a frame element at both ends of the wall structure.
 7. A soundproof booth, comprising walls comprising the wall structure of claim
 1. 8. A method of manufacturing the wall structure of claim 1, comprising: providing frame elements; and attaching the first dampening element, the first stopping element, the second dampening element, and the second stopping element in between the frame elements. 